Inner housing for electrical connector terminal cavity

ABSTRACT

An electrical connector assembly includes an electrical connector that defines a terminal cavity. The terminal cavity extends from an insertion opening to a mating opening. An inner housing is positioned in the terminal cavity. The inner housing defines an inner cavity. The inner cavity extends from an inner insertion opening to an inner mating opening. The inner mating opening is adjacent to the mating opening of the electrical connector. An electrical terminal is positioned in the inner cavity. A mating portion of the electrical terminal is adjacent the inner mating opening.

BACKGROUND OF THE INVENTION

The present invention relates in general to an inner housing for usewith an electrical connector. More specifically, this invention relatesto an inner housing that allows a cavity of an electrical connector tohold multiple electrical terminals.

Vehicles, such as passenger cars, include a variety of electricalcomponents that are provided for the operation of the vehicle, as wellas for the comfort and convenience of occupants. The vehicle includeselectrical connections to provide power and control signals for theseelectrical components. These electrical connections include wires,terminals, and connectors that house the terminals.

As technology has advanced, vehicles include a larger number ofelectrical components. As a result, vehicles require more electricalconnections. This can include connections for providing power, as wellas connections for providing control signals. Additionally, aselectrical components become more efficient, they can be powered usingsmaller electrical connections. Also, the electrical connections usedfor control signals are typically lower power than power connections. Asa result, vehicles have an increasing need for a larger number ofsmaller electrical connections.

The parts of vehicle electrical connections, including the terminals andhousings, are tested and approved by manufacturers before being used ona vehicle. These components are typically specified for use on a vehiclemodel over several years. When a component is changed, it is tested todetermine that it meets the manufacturer's requirements as well as toobtain any pertinent certification, which can add cost and delay to themanufacturing process. As a result, it can be desirable to themanufacturer to continue to use components that are already proven. Itwould be advantageous to use existing electrical components, whileincreasing the number of electrical connections that are made with thosecomponents.

SUMMARY OF THE INVENTION

This invention relates to an electrical connector assembly. Theelectrical connector assembly includes an electrical connector thatdefines a terminal cavity. The terminal cavity extends from an insertionopening to a mating opening. An inner housing is positioned in theterminal cavity. The inner housing defines an inner cavity. The innercavity extends from an inner insertion opening to an inner matingopening. The inner mating opening is adjacent to the mating opening ofthe electrical connector. An electrical terminal is positioned in theinner cavity. A mating portion of the electrical terminal adjacent theinner mating opening.

This invention also relates to an electrical connector assembly. Theelectrical connector assembly includes an electrical connector. Theelectrical connector defines a terminal cavity. The terminal cavityextends from an insertion opening to a mating opening. An inner housingis positioned in the terminal cavity. The inner housing defines an innercavity. The inner cavity extends from an inner insertion opening to aninner mating opening. The inner mating opening is adjacent to the matingopening of the electrical connector. The inner housing also defines asecond inner cavity. The second inner cavity extends from a second innerinsertion opening to a second inner mating opening. The second matingopening is adjacent to the mating opening of the electrical connector. Aterminal lock retains the inner housing in the terminal cavity. Asecondary lock attached to the electrical connector prevents release ofthe terminal lock. An electrical terminal is positioned in the innercavity. A mating portion of the electrical terminal is adjacent theinner mating opening. A second electrical terminal is positioned in thesecond inner cavity. A second mating portion of the second electricalterminal is adjacent the second inner mating opening.

Various aspects of this invention will become apparent to those skilledin the art from the following detailed description of the preferredembodiment, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a conventional three-way electricalconnector and a female electrical terminal for use therein.

FIG. 2 is a cut-away view of the three-way electrical connector showingthe cross-section of a first terminal cavity thereof.

FIG. 3 is a perspective view of two female electric terminals.

FIG. 4 is a perspective view of an inner housing that contains the twofemale electric terminals.

FIG. 5 is a perspective view of an electrical connector assembly whichincludes the three-way electrical connector and the inner housingpositioned in one of the terminal cavities.

FIG. 6 is a cut-away view of the electrical connector assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, there is illustrated in FIG. 1 aconventional electrical connector, indicated generally at 10. Theelectrical connector 10 includes a body 12 and three terminal cavities14 a, 14 b, and 14 c. Each of the terminal cavities 14 a, 14 b, and 14 cis adapted to accommodate an electrical terminal 16. The illustratedelectrical connector 10 is a three-way connector and is provided as oneexample of an electrical connector suitable for use with this invention.However, the electrical connector 10 may include any desired number ofterminal cavities. The illustrated electrical terminal 16 is a 2.8 mmfemale electrical terminal, and the electrical connector 10 is adaptedto accommodate the female electrical terminal 16. The electricalconnector 10 may be adapted to accommodate any desired size ofelectrical terminal 16 and may be adapted to accommodate male electricalterminals, if desired. The electrical connector 10 is adapted to bemated with a corresponding connector in a way that is known in the artin order to mate the electrical terminal 16 with a correspondingelectrical terminal (not shown) housed in the corresponding connector.In use, the electrical connector 10 may include one, two, or threeelectrical terminals 16, depending on the number of electricalconnections desired.

Referring now to FIG. 2, a cut-away view of the electrical connector 10is shown, cut along the length of the terminal cavity 14 a. The terminalcavity 14 a extends along a cavity axis 18 a (see FIG. 1) from aninsertion opening 20 to a mating opening 22. The terminal cavities 14 band 14 c extend along respective cavity axes 18 b and 18 c from similarinsertion openings to similar mating openings. The terminal cavity 14 aincludes a terminal lock 24 that serves to retain the electricalterminal 16 in an installed position within the terminal cavity 14 a.The illustrated terminal lock 24 is a deflectable arm, but may be anydesired locking mechanism. As is known, the electrical terminal 16 isplaced in the installed position within the terminal cavity 14 a bybeing inserted into the terminal cavity 14 a through the insertionopening 20. The terminal lock 24 is deflected by the electrical terminal16 and rebounds to engage a catch 26 on the electrical terminal 16, asshown in FIG. 1.

The electrical connector 10 also includes an optional secondary lock 28.As is known, the secondary lock 28 is inserted into the body 12 afterthe electrical terminal 16 is in the installed position. The secondarylock 28 includes a locking flange 30 that blocks deflection of theterminal lock 24 in order to prevent the terminal lock 24 from releasingthe electrical terminal 16. The secondary lock 28 also acts as aterminal position assurance. If the electrical terminal 16 is not fullyinserted to the installed position, the terminal lock 24 will not fullyrebound to engage the catch 26, and the locking flange 30 will buttagainst the terminal lock 24 to prevent insertion of the secondary lock28 into the body 12, as is known. In the illustrated embodiment, asingle secondary lock 28 is provided for all three terminal cavities 14a, 14 b, and 14 c, but the electrical connector 10 may include anydesired number of secondary locks 28.

Referring to FIG. 3, there is shown a perspective view of a replacementelectrical terminal 32 a and a second replacement electrical terminal 32b. The replacement electrical terminal 32 a and the second replacementelectrical terminal 32 b are substantially identical and, therefore,will not be described separately. The replacement electrical terminal 32a will be described in detail, and similar components of the secondreplacement electrical terminal 32 b will be identified on the drawingsby the similar number with the “b” suffix.

The illustrated replacement electrical terminal 32 a is a 0.5 mm femaleelectrical terminal. However, the replacement electrical terminal 32 amay be any desired size, and may be any desired type of electricalconnector. The replacement electrical terminal 32 a is attached to awire 34 a by crimping, but may be attached to any desired conductor byany desired type of connector. The replacement electrical terminal 32 aextends along a replacement terminal axis 36 a and is adapted to matewith a replacement corresponding terminal (not shown) inserted into amating portion 38 a.

Referring to FIG. 4, a perspective view of an inner housing, indicatedgenerally at 40, is shown. The illustrated inner housing 40 is a singlepiece molded from plastic, but may be made of any desired material andby any desired method. The inner housing 40 includes a body 42. Theinner housing 40 defines an inner cavity 48 a that extends from an innerinsertion opening 44 a to an inner mating opening 46 a. The innerhousing 40 also defines a second inner cavity 48 b, which is separatedfrom the first inner cavity 48 a by an optional inner wall 50. The innercavity 48 a will be described in detail, and similar components of thesecond inner cavity 48 b will be identified on the drawings by thesimilar number with the “b” suffix. Although not visible in FIG. 4, thereplacement electrical terminal 32 a is located in the inner cavity 48a, with the mating portion 38 a adjacent to the inner mating opening 46of the inner housing 40. Similarly, the second replacement electricalterminal 32 b is located in the second inner cavity 48 b.

The inner housing 40 includes an inner terminal lock 52 a, which servesto retain the replacement electrical terminal 32 a in an installedposition in the inner cavity 48 a. The illustrated inner terminal lock52 a is a deflectable arm, but may be any desired locking mechanism. Thereplacement electrical terminal 32 a is placed in the installed positionwithin the inner cavity 48 a by being inserted into the inner cavity 48a through the inner insertion opening 44 a of the inner housing 40. Theinner terminal lock 52 a is deflected by the replacement electricalterminal 32 a and rebounds to engage a terminal catch 54 a on thereplacement electrical terminal 32 a, shown in FIG. 3. Alternatively,the replacement electrical terminal 32 a may be retained in the innerhousing 40 by making the replacement electrical terminal 32 a integralwith the inner housing 40, for example, by molding the inner housing 40around the replacement electrical terminal 32 a.

Referring to FIG. 5, a perspective view of an electrical connectorassembly, indicated generally at 56, is shown. The electrical connectorassembly 56 includes the electrical connector 10 with the inner housing40 positioned in the terminal cavity 14 a. A cut-away view of theelectrical connector assembly 56 is shown in FIG. 6, cut along thecenterline of the inner cavity 48 a. A wall 60 of the terminal cavity 14a blocks deflection of the inner terminal lock 52 a and acts as an innersecondary lock to prevent the replacement electrical terminal 32 a frombeing removed from the inner housing 40. In the illustrated embodiment,the wall 60 is the terminal lock 24, but may be any desired portion ofthe terminal cavity 14 a.

The terminal lock 24 in the terminal cavity 14 a also serves to retainthe inner housing 40 in an installed position within the terminal cavity14 a. The inner housing 40 is placed in the installed position withinthe terminal cavity 14 a by being inserted into the terminal cavity 14 athrough the insertion opening 20. The terminal lock 24 is deflected bythe inner housing 40 and rebounds to engage a housing catch 58 on theinner housing. Additionally, the secondary lock 28 of the electricalconnector 10 will prevent the inner housing 40 from being removed fromthe terminal cavity 14 a and will also act as a position assurance forthe inner housing 40. If the inner housing 40 is not fully inserted tothe installed position, the terminal lock 24 will not fully rebound toengage the housing catch 58 and the locking flange 30 will butt againstthe terminal lock 24 to prevent insertion of the secondary lock 28 intothe body 12.

The replacement electrical terminal 32 a is positioned in the terminalcavity 14 a so that the replacement terminal axis 36 a is substantiallyparallel to the cavity axis 18 a. The replacement terminal axis 36 a isoriented to pass through the mating opening 22 of the electricalconnector 10. Additionally, the second replacement electrical terminal32 b is positioned in the terminal cavity 14 b so that the secondreplacement terminal axis 36 b is substantially parallel to the cavityaxis 18 b. The second replacement terminal axis 36 b is also oriented topass through the mating opening 22 of the electrical connector 10.

The electrical connector assembly 56 is illustrated with one innerhousing 40 placed in one terminal cavity 14 a, but the illustratedelectrical connector assembly 56 may have additional inner housings 40placed in the other terminal cavities 14 b and 14 c. Although not shown,the corresponding connector will have similar modifications in order tohouse electrical terminals that correspond to the replacement electricalterminal 32 a and the second replacement electrical terminal 32 b. Theuse of the inner housing 40 allows the electrical connector assembly 56to house a larger number of electrical terminals, while still utilizingthe same electrical connector 10.

The principle and mode of operation of this invention have beenexplained and illustrated in its preferred embodiment. However, it mustbe understood that this invention may be practiced otherwise than asspecifically explained and illustrated without departing from its spiritor scope.

What is claimed is:
 1. An electrical connector assembly comprising: anelectrical connector defining a terminal cavity that extends from aninsertion opening to a mating opening and that includes an integralterminal lock that extends into the terminal cavity; an inner housingpositioned in the terminal cavity, the inner housing defining an innercavity that extends from an inner insertion opening to an inner matingopening that is adjacent to the mating opening of the electricalconnector, the integral terminal lock of the electrical connectorengaging the inner housing and thereby preventing the inner housing frombeing removed from the terminal cavity; and an electrical terminalpositioned in the inner cavity with a mating portion of the electricalterminal adjacent the inner mating opening.
 2. The electrical connectorassembly of claim 1, wherein the inner housing includes an innerterminal lock that retains the electrical terminal in the inner cavity.3. The electrical connector assembly of claim 2, wherein a wall of theelectrical connector is a secondary lock to prevent release of the innerterminal lock.
 4. The electrical connector assembly of claim 1, whereinthe inner housing defines a second inner cavity and a second electricalterminal is positioned in the second inner cavity with a second matingportion adjacent the mating opening.
 5. The electrical connectorassembly of claim 4, wherein the terminal cavity extends along a cavityaxis, the electrical terminal extends along a terminal axis that isparallel to the cavity axis, and the second electrical terminal extendsalong a second terminal axis that is parallel to the cavity axis.
 6. Theelectrical connector assembly of claim 5, wherein the terminal axisextends through the mating opening of the electrical connector and thesecond terminal axis extends through the mating opening of theelectrical connector.
 7. The electrical connector assembly of claim 5,wherein the inner housing includes an inner terminal lock that retainsthe electrical terminal in the inner cavity and a second inner terminallock that retains the second electrical terminal in the second innercavity.
 8. The electrical connector assembly of claim 7, wherein a wallof the electrical connector is a secondary lock to prevent release ofthe inner terminal lock and the second inner terminal lock.
 9. Anelectrical connector assembly comprising: an electrical connectordefining a terminal cavity that extends from an insertion opening to amating opening; an inner housing positioned in the terminal cavity, theinner housing defining an inner cavity that extends from an innerinsertion opening to an inner mating opening that is adjacent to themating opening of the electrical connector; a terminal lock formedintegrally with the electrical connector and extending into the terminalcavity, the terminal lock engaging the inner housing and therebypreventing the inner housing from being removed from the terminalcavity; a secondary lock attached to the electrical connector whichblocks deflection of the terminal lock in order to prevent the innerhousing from being removed from the terminal cavity; an electricalterminal positioned in the inner cavity with a mating portion of theelectrical terminal adjacent the inner mating opening.
 10. Theelectrical connector assembly of claim 9, wherein the terminal cavityextends along a cavity axis that extends through the mating opening, theelectrical terminal extends along a terminal axis that is parallel tothe cavity axis and extends through the mating opening, and the secondelectrical terminal extends along a second terminal axis that isparallel to the cavity axis and extends through the mating opening. 11.An electrical connector assembly comprising: an electrical connectordefining a terminal cavity that extends from an insertion opening to amating opening and that includes an integral terminal lock that extendsinto the terminal cavity, the electrical terminal including a catch; aninner housing positioned in the terminal cavity, the inner housingdefining an inner cavity that extends from an inner insertion opening toan inner mating opening that is adjacent to the mating opening of theelectrical connector, wherein the inner housing includes an innerterminal lock; and an electrical terminal positioned in the inner cavitywith a mating portion of the electrical terminal adjacent the innermating opening, wherein the inner terminal lock retains the electricalterminal in the inner cavity and wherein the integral terminal lock ofthe electrical connector engages the inner housing thereby preventingthe inner housing from being removed from the terminal cavity andwherein a wall of the electrical connector is a secondary lock thatprevents release of the inner terminal lock thereby preventing theelectrical terminal from being removed from the inner housing.